Foaming die device adapted to effect foaming in trim cover assembly integrally to form headrest, and foaming process for forming headrest by effecting foaming in trim cover assembly integrally, using the foaming die device

ABSTRACT

A foaming die device for forming a headrest is provided, which comprises a lower die having a first protrusion and an upper die having a second protrusion. The lower and upper dies are used for accommodating a trim cover assembly with a headrest stay portion extending outwardly through a stay passage hole formed in the trim cover assembly. The first and second protrusions are adapted to press and turn over a projected area created about the stay passage hole into the inside of that trim cover assembly. Also, a foaming process for forming the headrest, using this foaming die device, is provided, in which the projected area is turned over by the first and second protrusions into the trim cover assembly when placing the trim cover assembly in the dies. Hence, conventional preliminary steps using cylindrical stick to turn over the projected area into the trim cover assembly are eliminated.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional under 37 C.F.R. §1.53(b) of prior U.S. patent application Ser. No. 14/298,325, filed Jun. 6, 2014, which claims priority to Japanese Patent Application No. 2013-128114, filed Jun. 19, 2013. The contents of each of these applications are incorporated in full by reference herein.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a foaming die device adapted to effect foaming in a headrest trim cover assembly (or a surface covering element for headrest) in an integral manner to form a headrest for use with an automotive seat, and also relates to a foaming process for forming the headrest, which entails forming a foam padding in the headrest trim cover assembly in an integral manner, using the foaming die device.

2. Description of Prior Art

For example, Japanese Laid-Open Publication No. 2012-245081 (JP 2012-245081 A) discloses a typical conventional process for forming a headrest for use with an ordinary automotive seat, which includes the step of installing a substantially U-shaped headrest stay in a trim cover assembly preformed in a bag-like three-dimensional shape, prior to the step of placing the trim cover assembly in a foaming die device. As usually found in the art, such substantially U-shaped headrest stay includes a pair of substantially-rectilinear stay portions (hereinafter, it shall be referred to as “first substantially-rectilinear stay portion” and “second substantially-rectilinear stay portion”) formed integrally therewith, which are adapted to be mounted in a seat back. On the other hand, the trim cover assembly is formed with a pair of stay passage holes (hereinafter, it shall be referred to as “first stay passage hole” and “second passage hole”) adapted for allowing the first and second substantially-rectilinear stay portions to be inserted therein and passed therethrough, respectively.

According to the conventional process, at first, a worker inserts the first substantially-rectilinear stay portion of the headrest stay into the second stay passage hole of the trim cover assembly, wherein the second stay passage hole is a hole in which the second substantially-rectilinear stay portion normally exists when the headrest stay is installed in the trim cover assembly. Then, the worker manages to continue on pushing that first substantially-rectilinear stay portion, via the second stay passage hole, into the inside of the trim cover assembly and causing the same to advance within the trim cover assembly towards the first stay passage hole, so that the first substantially-rectilinear stay portion eventually projects outwardly from the trim cover assembly through that first stay passage hole, while ascertaining that the second substantially-rectilinear stay portion passes through and yet remains in the earlier-stated second stay passage hole. In that way, the headrest stay is installed within the trim cover assembly, such that both first and second substantially-rectilinear stay portions pass through the first and second stay passage holes, respectively, and project outwardly from the trim cover assembly. Next, a foaming die device is provided, which has upper and lower dies. The trim cover assembly with the headrest stay thus installed therein is placed in and between two cavity regions respectively of the upper and lower dies, and then, the upper and lower dies are closed and mated with each other. Thereafter, a liquid foaming agent is injected via an injection nozzle into the inside of the trim cover assembly placed in those upper and lower dies and cured to form a foam padding filled in that trim cover assembly in an integral manner, so that a resulting headrest for automotive seat is produced.

However, in the above-described conventional headrest production process, at the step of pushing the first and second substantially-rectilinear stay portions outwardly through the first and second stay passage holes, respectively, prior to the trim cover assembly being placed in the dies, there has been a problem in that, when the first and second substantially-rectilinear stay portions are inserted in and passed through the respective first and second stay passage holes, a peripheral edge portion of each of the first and second stay passage holes, by the reason of its being in frictional contact about the corresponding substantially-rectilinear stay portion, is forcibly stretched outwardly from the outer surface of trim cover assembly. As a result thereof, a cylindrically projected local area is created in the peripheral end of each of the first and second stay passage holes and laid on and about the corresponding substantially-rectilinear stay portion outside of the trim cover assembly. Such cylindrically projected local area is therefore exposed exteriorly of the trim cover assembly, which undesirably impairs an outer aesthetic appearance of a resulting headrest. To avoid creation of the cylindrically projected local area, before placing the trim cover assembly in the dies, it is required or customary in the past for a worker to use a cylindrical stick for the purpose of pressing and turning over such cylindrically projected local area into the inside of the trim cover assembly. That is, the worker causes each of the first and second substantially-rectilinear stay portions to insert in a through-bore of such cylindrical stick and moves the cylindrical stick along the substantially-rectilinear stay portion towards the trim cover assembly, to the extent that the circular distal end of that cylindrical stick contacts and presses the afore-said cylindrically projected local area. Then, the worker continues to move the cylindrical stick further, so that a whole of the cylindrically projected local area is turned over reversely relative to the stay passage hole and positioned inside of the trim cover assembly, thereby avoiding external exposure of that cylindrically projected local area. In that way, the outer peripheral region of each of the first and second stay insertion holes is made flat and even on the outer surface of the trim cover assembly, hence maintaining the outer aesthetic appearance of resulting headrest. This is an ordinary conventional means to avoid external exposure of the afore-said projected area in question, which is created about each of the first and second stay passage holes. However, such conventional method has imposed annoying inefficient steps upon the workers, because he or she is compelled to use the cylindrical sticks for each of many trim cover assemblies, troublesomely, prior to the step of placing the trim cover assembly in the foaming die device.

SUMMARY OF THE INVENTION

In view of the afore-stated drawbacks, it is a first purpose of the present invention to provide a foaming die device for forming a headrest, which eliminates the above-described conventional preliminary steps for turning over the afore-said projected area in question into the inside of a trim cover assembly, prior to the step of placing the trim cover assembly in the foaming die device.

In order to achieve such purpose, in accordance with the present invention, there is provided a foaming die device so constructed as to allow accommodation therein of a trim cover assembly in which a headrest stay is installed therein such that at least one stay portion of the headrest stay passes through at least one stay passage hole of said trim cover assembly and is exposed exteriorly of the trim cover assembly, wherein a projected area is created in a peripheral end of the at least one stay passage hole and laid on and about the at least one stay portion so as to be exposed exteriorly of the trim cover assembly, and further allow a liquid foaming agent to be injected into an inside of the trim cover assembly and cured therein, to thereby form a headrest having the at least one stay portion exposed exteriorly thereof,

-   -   the foaming die device basically comprising:         -   an upper die having a cavity region and a second mating             surface;         -   a lower die having a cavity region and a first mating             surface adapted to be mated with the second mating surface             of the upper die;         -   the upper and lower dies being able to be mated with and             separated from each other;         -   wherein, when the upper and lower dies are mated with each             other, a cavity is defined between the cavity region of the             upper die and the cavity region of the lower die, the cavity             being of such a dimension as to accommodate a whole of the             trim cover assembly therein,         -   a first stay receiving recession formed in the first mating             surface of the lower die, the first stay receiving recession             being so configured to receive the at least one stay             portion;         -   a second stay receiving recession formed in the second             mating surface of the upper die, the first stay receiving             recession being so configured to receive the al least one             stay portion;         -   a first protrusion provided in the lower die, the first             protrusion protruding in a direction from an inner wall of             the lower die towards the cavity region of the lower die;         -   a second protrusion provided in the upper die, the second             protrusion protruding in a direction from an inner wall of             the upper die towards the cavity region of the upper die;             and         -   the first and second protrusions being adapted to press and             turn over the projected area relative to the at least one             stay passage hole into the inside of the trim cover             assembly.

Accordingly, when pressing a bottom wall of the trim cover assembly′ against the inner wall of the upper die towards the first and second protrusions, it is to be appreciated that such first and second protrusions are inserted into the at least one stay passage hole, which in turn causes the afore-said projected area to turn over in relation to the said one stay passage hole, with the result that the projected area is entirely folded into the inside of the trim cover assembly and positioned therein. Thereafter, the upper die is mated with the lower die to close the foaming die device, so that the at least one stay portion is partly sandwiched by the first and second stay receiving recessions. In other words, a worker has only to set the trim cover assembly in the cavity of the foaming die device and simply cause the projected areas exposed exteriorly of the trim cover assembly to turn over at the first and second protrusions relative to the at least one stay passage hole into the inside of the trim cover assembly. This eliminates the previously-described conventional preliminary steps requiring troublesome use of cylindrical sticks to turn over the projected area into the inside of trim cover assembly.

It is a second purpose of the present invention to permit easy and assured insertion of the first and second protrusions into the at least one stay passage hole in the longitudinal direction of the at least one stay portion.

For that purpose, the first protrusion may be so formed to become small in thickness as it proceeds to an distal end thereof and have an extension surface forming one part of a wall surface of a first wall which defines the first stay receiving recession, whereas the first protrusion be so formed to become small in thickness as it proceeds to an distal end thereof and have an extension surface forming one part of a wall surface of a second wall which defines the second stay receiving recession.

As another preferred aspect of the invention, a first stay receiving element may be securely provided to the lower die, the first stay receiving element being adapted to receive the afore-said at least one stay portion, whereas a second stay receiving element be securely provided to the upper die, the second stay receiving element being adapted to receive the at least one stay portion. In this mode, the first stay receiving element comprises: a body portion secured to the lower die; and the afore-said first protrusion, wherein the first protrusion protrudes from the body portion towards the cavity region of the lower die, whereas the second stay receiving element comprises: a body portion secured to the upper die; and the afore-said second protrusion, wherein the second protrusion protrudes from the body portion towards the cavity region of the upper die. With this arrangement, when the first and second stay receiving elements become worn out of use, it is easily possible to replace them all or either of them by new corresponding stay receiving element (s). Moreover, one or both of the two stay receiving elements can be modified in terms of technical design and specifications, as required.

As still another preferred aspect of the invention, the afore-said body portion and first protrusion of the first stay receiving element as well as the afore-said body portion and second protrusion of the second stay receiving element may be formed in a substantially semi-cylindrical shape. Also, the body portions respectively of the first and second stay receiving elements may be securely connected to the lower and upper dies, respectively, by at least one securing screw. This arrangement allows the first and second stay receiving elements to be easily secured and removed from the lower and upper dies, respectively, by use of the at least one screw, thus enabling a worker to easily replace one or both of those two stay receiving elements by a new corresponding stay receiving element (s).

It is a third purpose of the present invention to provide a foaming process for forming a headrest, which eliminates the above-described preliminary steps using the cylindrical sticks to press the afore-said projected area in question into the inside of a trim cover assembly, prior to the step of placing the trim cover assembly in the foaming die device.

To achieve such purpose, in accordance with the present invention, there is basically provided the steps of:

providing a foaming die device comprising: an upper die having a cavity region defined therein; and a lower die having a cavity region defined therein, the upper and lower dies being able to be mated with and separated from each other; wherein a first protrusion is provided in the lower die so as to protrude in a direction from an inner wall of the lower die towards the cavity region of the lower die, whereas a second protrusion is provided in the upper die so as to protrude in a direction from an inner wall of the upper die towards the cavity region of the upper die;

-   -   providing a headrest stay having at least one stay portion         extending therefrom;     -   providing a trim cover assembly having at least one stay passage         hole adapted to allow the at least one stay portion to pass         therethrough;     -   installing the headrest stay within the trim cover assembly,         such that the at least one stay portion of the headrest stay         passes through the at least one stay passage hole and extends         outwardly of the trim cover assembly, with a projected area         being created in a peripheral end of the at least one stay         passage hole and laid on the at least one stay portion so as to         be exposed exteriorly of the trim cover assembly;     -   thereafter, placing the trim cover assembly with the headrest         stay thus installed therein, in a cavity defined between the         cavity region of the upper die and the cavity region of the         lower die, such that the first and second protrusions are         inserted into the at least stay passage hole of the trim cover         assembly, thereby causing the projected area to turn over         relative to the at least one stay passage hole into the inside         of the trim cover assembly; and     -   thereafter, injecting a liquid foaming agent into the inside of         the trim cover assembly and curing the liquid foaming agent into         an increased mass of foam padding filled in the trim cover         assembly.

By the virtue of the above-described steps, the first and second protrusions can be easily inserted into the at least one stay passage hole, which in turn causes the afore-said projected area in question to turn over in relation to the said one stay passage hole, with the result that the projected area is entirely folded into the inside of the trim cover assembly and positioned therein. Therefore, a worker has only to set the trim cover assembly in the cavity of the foaming die device and simply cause the projected area exposed exteriorly of the trim cover assembly to turn over at the first and second protrusions relative to the at least one stay passage hole into the inside of the trim cover assembly. This eliminates the previously-described conventional preliminary steps requiring troublesome use of cylindrical sticks to turn over the projected area into the inside of trim cover assembly.

Other various features and advantages will become apparent from reading of the description, hereinafter, with reference to the accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partly broken perspective view of a headrest which is formed by a foaming die device in accordance with the present invention;

FIG. 2 is a sectional view showing one exemplary mode of the foaming die device;

FIG. 3 is a partly broken perspective view showing a stay receiving element provided in a lower die of the foaming die device;

FIG. 4 is a fragmentary sectional view showing the stay receiving element provided in the lower die;

FIG. 5 is a sectional view showing a state where a trim cover assembly is placed in upper and lower dies of the foaming die device;

FIG. 6 is a sectional view showing a state where a liquid foaming agent has been injected and cured in the trim cover assembly placed in the upper and lower dies;

FIG. 7 is a partly broken perspective view showing another mode of stay receiving element provided in the lower die of the foaming die device; and

FIG. 8 is a fragmentary sectional view showing such another mode of stay receiving element provided in the lower die.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION

FIG. 1 shows a resulting headrest HR formed under a foaming process in accordance with the present invention. The headrest HR has: a trim cover assembly 2 formed by sewing several cover materials together in a bag-like three-dimensional shape; a foam padding 3 which is formed in the trim cover assembly 2 under the steps of injecting a liquid foaming agent (e.g. a liquid urethane material capable of being foamed) into the inside of the trim cover assembly 2 and then curing the liquid foaming agent to form an increased mass of the foam padding 3 filled in the trim cover assembly; and a headrest stay 5 securely provided within the foam padding 3.

While not shown clearly, the trim cover assembly 2, which forms a surface cover of the headrest, is of a two-layer lamination construction consisting of: a top cover member made of an unbreathable, impermeable synthetic leather material; and a foam wadding affixed on the reverse surface of that top cover member, the foam wadding being made of a slab urethane foam material. The headrest stay 5 is formed in a substantially “U” configuration which has: a substantially U-shaped body portion 5 c embedded in the foam padding 3; and a pair of substantially-rectilinear stay portions 5 a and 5 b (which shall hereinafter be referred to as “a first substantially-rectilinear stay portion 5 a” and “a second substantially-rectilinear stay portion 5 b”, respectively). As seen in FIG. 1, in the bottom wall 2 c of the trim cover assembly 2, there are formed a pair of stay passage holes 2 a and 2 b (which shall hereinafter be referred to as “a first stay passage hole 2 a” and “a second stay passage hole 2 b”, respectively). The first and second substantially-rectilinear stay portions 5 a and 5 b are shown as passing through the first and second stay passage holes 2 a and 2 b, respectively, and being exposed exteriorly of the trim cover assembly 2.

FIG. 2 shows a foaming die device 1 by which the trim cover assembly 2 with the headrest stay 5 installed therein as stated above can be subjected to foaming in integral manner. By use of such foaming die device 1, the above-described headrest HR is formed. This foaming die device 1 comprises an upper die 20 and a lower die 10. The upper and lower dies 20 and 10 are hingedly connected by a hinge 6 with each other, so that the upper die 20 can be moved away from the lower die 10 to open the foaming die device 1 and mated therewith to close the latter 1. As shown, each of the upper and lower dies 20 and 10 has a cavity region defined therein, and therefore, when the upper and lower dies 20 and 10 are mated with each other, a cavity C is defined therebetween. The cavity C is so configured to accommodate an entirety of the trim cover assembly 2 therein. The upper die 10 has a first mating surface 10 a, whereas the upper die 20 has a second mating surface 20 a. When mating the upper die 20 with the lower die 10 to close the foaming die device 1, such two mating surfaces 10 a and 20 a are mated and contacted with each other closely. The lower die 10 is provided with a first stay receiving element 30 in the first mating surface 10 a thereof, wherein the first stay receiving element 30 is so configured to receive a part of lower half of the substantially-rectilinear stay portion of the headrest stay 5. On the other hand, the upper die 20 is provided with a second stay receiving element 40 in the second mating surface 20 a thereof, wherein the second stay receiving element 40 is so configured to embracingly overlie a part of upper half of the substantially-rectilinear stay portion of the headrest stay 5.

As best shown in FIGS. 3 and 4, the first stay receiving element 30 is fixedly secured by securing screws 11 to the lower die 10. Specifically, the lower die 10 is formed with a recession 10 b of semicircular cross-section, whereas the first stay receiving element 30 has a first semi-cylindrical main portion 30 a defined therein. The first semi-cylindrical main portion 30 a is secured fit in the recession 10 b of the lower die 10. Further, the first stay receiving element 30 has a semi-cylindrical protrusion 30 b. This semi-cylindrical protrusion 30 b is shown as protruding in a direction from an inner wall 12 of the lower die 10 towards the cavity region of the lower die 10 which forms one of the cavity C. As will be described later, by means of such semi-cylindrical protrusion 30 b, a cylindrically projected area A created from and about each of the first and second stay passage holes 2 a and 2 b can be forcibly turned over into the inside of the trim cover assembly 2.

As shown, the first semi-cylindrical main portion 30 a is received in the recession 10 b and fixedly secured thereto by two securing screws 11 and 11.

Prior to a foaming process using the foaming die device 1, while not shown, there are the steps of providing a hollow trim cover assembly 2 with the headrest stay 5 installed therein, such that both first and second substantially-rectilinear stay portions 5 a and 5 b of the headrest stay 5 project outwardly from the trim cover assembly 2. In such preliminary steps, as normally done in the art, a worker inserts the first substantially-rectilinear stay portion 5 a into the second stay passage hole 2 b of the trim cover assembly 2 and then manages to continue on pushing that first substantially-rectilinear stay portion 5 a, via the second stay passage hole 2 b, into the inside of the trim cover assembly 2 and causing that stay portion 5 a to advance within the trim cover assembly 2 towards the first stay passage hole 2 a, so that the first substantially-rectilinear stay portion 5 a projects outwardly from the trim cover assembly 2 through the second stay passage hole 2 b, while ascertaining that the second substantially-rectilinear stay portion 5 b passes through and yet remains in the earlier-stated first stay passage hole 2 a. In that way, the headrest stay 5 is installed within the trim cover assembly 2 which is hollow inside thereof at this stage, such that both first and second substantially-rectilinear stay portions 5 a and 5 b thereof are exposed exteriorly of the trim cover assembly. It is noted here that the first and second substantially-rectilinear stay portions 5 a and 5 b are closely contacted with the first and second stay passage holes 2 a and 2 b, respectively. Therefore, as previously stated in the description of prior art, at the above-described step of pushing the first and second substantially-rectilinear stay portions 5 a and 5 b outwardly through the first and second stay passage holes 2 a and 2 b, respectively, it is inevitable that both two peripheral edges respective of those first and second stay passage holes 2 a and 2 b are forcibly stretched in a direction outwardly of the trim cover assembly 2. As a result thereof, a cylindrically projected area is created from and about each of the first and second stay passage holes 2 a and 2 b. In other words, a pair of such cylindrically projected areas respective of the two stay passage holes 2 a and 2 b are laid on and about the two substantially-rectilinear stay portions 5 a and 5 b, respectively, thus projecting outwardly of the trim cover assembly 2. Such two cylindrically projected areas can be recognized by the designations A and A in the drawings.

Next, the above-stated hollow trim cover assembly 2 with the two cylindrically projected areas A and A exposed exteriorly thereof is placed in the cavity region of the lower die 10, wherein the cavity region forms one of the cavity C as stated earlier. At this point, the first semi-cylindrical protrusion 30 b, which protrudes in a direction from the inner wall 12 to the cavity region of the lower die 10, enters the first stay passage hole 2 a. Consequently, as will be elaborated later, the cylindrically projected area A, created about the first stay passage hole 2 a and exposed exteriorly of the trim cover assembly 2, is pressed by that first semi-cylindrical protrusion 30 b, so that the cylindrically projected area A is forcibly turned over relative to the stay passage hole 2 a into the inside of the trim cover assembly 2.

The first stay receiving element 30 has: a first stay receiving recession 30 c of semi-circular cross-section, which is adapted to receive the first substantially-rectilinear stay portion 5 a of the headrest stay 5; and a pair of mating surfaces 30 d and 30 d defined flush with the first mating surface 10 a of the lower die 10, wherein such pair of mating surfaces 30 d are situated on the opposite sides of and symmetrically relative to the first stay receiving recession 30 c, as shown.

The first semi-cylindrical protrusion 30 b is tapered or so formed to become mailer in thickness as it proceeds to the distal end thereof. This first semi-cylindrical protrusion 30 b has: a first extension surface region B which forms one local area of first and second surfaces 30A that define the first stay receiving recession 30 c therein; and a curved surface F which is defined in the undersurface of the first extension surface region B so as to coverage from the outer surface of the semi-cylindrical protrusion 30 b towards the distal end thereof. Such curved surface F functions to cause the cylindrically projected area A to turn over curvilinearly therealong in a direction to the inside of the trim cover assembly 2, as will be described later.

Although not shown, a pair of the aforementioned first stay receiving elements 30 and 30 are actually provided in the first mating surface 10 a of the lower die 10, such that one thereof is situated on the left, while the other thereof situated on the right. In other words, the left- and right-side first stay receiving elements 30 and 30 are provided in the lower die 10. It is to be understood that the right-side first stay receiving element 30 is so configured to receive a part of lower half of the first substantially-rectilinear stay portion 5 a, whereas the left-side first stay receiving element 30 so configured to receive a part of lower half of the second substantially-rectilinear stay portion 5 b. Also, though not shown, a pair of the aforementioned second stay receiving elements 40 and 40 are actually provided in the second mating surface 20 a of the upper die 20, such that one thereof is situated on the left, while the other thereof situated on the right. In other words, the left- and right-side second stay receiving elements 40 and 40 are provided in the upper die 20. It is to be understood that the right-side second stay receiving element 40 is so configured to embracingly overlie a part of upper half of the first substantially-rectilinear stay portion 5 a, whereas the left-side first stay receiving element 40 so configured to embracingly overlie a part of lower half of the second rectilinear stay portion 5 b. Hence, it is to be understood that, when mating the upper die 20 with the lower die 10, the first substantially-rectilinear stay portion 5 a is partly sandwiched between the right-side first and second stay receiving elements 30 and 40, whereas the second substantially-rectilinear stay portion 5 b partly sandwiched between the left-side first and second stay receiving elements 30 and 40.

With regard to the second stay receiving element 40, any further detailed description is omitted as to its second stay receiving recession 40 c, second semi-cylindrical main portion 40 a, and second semi-cylindrical protrusion 40 b having a second extension surface region D, since this second stay receiving element 40 is identical in shape and structure to the first stay receiving element 30. (See FIG. 2)

A description will be made of a process for forming a headrest HR by use of the foaming die device 1. As shown in FIG. 2, the upper die 20 is moved away from the lower die 10 to open the foaming die device 1. Thereafter, as seen in FIG. 5, a hollow trim cover assembly 2 with the headrest stay 5 installed therein as described earlier is placed and set in a cavity C defined between the two cavity regions of the upper and lower dies 20 an 10. This is a closed state of the foaming die device 1, in which the upper die 20 is mated with the lower die 10. But, prior thereto, it is to be understood that the two cylindrically projected areas A and A have been created from and about the first and second stay passage holes 2 a and 2 b of the trim cover assembly 2, respectively, thus projecting outwardly of the trim cover assembly 2, due to the reasons stated previously, and that, when placing the trim cover assembly 2 in the cavity region of the lower die 10, a worker should first press the bottom wall 2 c of the trim cover assembly 2 against the left- and right-side first semi-cylindrical protrusions 30 b and 30 b and then place two lower half regions respective of the first and second rectilinear stay portions 5 a and 5 b of the headrest stay 5 in the right- and left-side first stay receiving recessions 30 c and 30 c of the lower die 10, respectively.

While not shown, at this stage, when the worker presses the trim cover assembly's bottom wall 2 c against the inner wall of the lower die 10 towards the afore-said pair of first semi-cylindrical protrusions 30 b and 30 b, it is to be understood that the two first semi-cylindrical protrusions 30 b and 30 b are inserted into the first and second stay passage holes 2 a and 2 b, respectively, which in turn causes the two lower halves of the afore-said two cylindrically projected areas A and A to turn over relative to those two holes 2 a and 2 b, respectively, with the result that all the two lower halves of the two cylindrically projected areas A and A are entirely folded into the inside of the trim cover assembly 2 and positioned therein. Thereafter, it is to be understood that the worker moves the upper die 20 towards the lower die 10 in which the trim cover assembly 2 has been placed as above, in such a way that the inner wall of the upper die 20, where the left- and right-side second semi-cylindrical protrusions 40 b and 40 b exist, comes to contact with the bottom wall 2 c of the trim cover assembly 2.

At this point, though not shown, as the inner wall of the upper die 20 comes to contact with the bottom wall 2 c of the trim cover assembly 2, it is to be understood that the right- and left-side second semi-cylindrical protrusions 40 b and 40 b are inserted into the first and second stay passage holes 2 a and 2 b, respectively, which in turn causes two upper halves respective of the two cylindrically projected areas A and A to turn over in relation to those two holes 2 a and 2 b, respectively, with the result that all the two upper halves of the two cylindrically projected areas A and A are entirely folded into the inside of the trim cover assembly 2 and positioned therein. Subsequent thereto, the upper die 20 is completely mated with the lower die 10 to close the foaming die device 1, so that two upper half regions respective of the first and second rectilinear stay portions 5 a and 5 b are partly covered by the right- and left-side second stay receiving recessions 40 c and 40 c of the upper die 20, respectively, in an embraced manner. Hence, it is to be understood that a whole of the trim cover assembly 1 is securely placed within the cavity C, and the first substantially-rectilinear stay portion 5 a is sandwiched between the right-side first and second stay receiving recessions 30 c and 40 c, whereas the second substantially-rectilinear stay portion 5 b sandwiched between the left-side first and second stay receiving recessions 30 c and 40 c. It is therefore to be appreciated that, a worker has only to set the hollow trim cover assembly 1 in the cavity C of the foaming die device 1 and simply cause the two cylindrically projected areas A and A exposed exteriorly of the trim cover assembly to turn over at the first and second semi-cylindrical protrusions 30 b and 40 b relative to the two stay passage holes 2 a and 2 b, respectively, into the inside of the trim cover assembly 1. This eliminates the previously-described conventional preliminary steps requiring troublesome use of cylindrical sticks to press and turn over the cylindrically projected areas into the inside of trim cover assembly.

Thereafter, as shown in FIGS. 5 and 6, a liquid foaming agent is injected, via an injection nozzle 45 inserted in the lower die 10, into the inside of the trim cover assembly 2 and cured to form an increased mass of foam padding 3 filled in trim cove assembly 2. During this foaming process, both two cylindrically projected areas A and A, which project interiorly of the trim cover assembly 2, are forcibly brought by such increased mass of foam padding 3 to close contact about the first and second substantially-rectilinear stay portions 5 a and 5 b of the headrest stay 5, respectively. Thereby, all those two cylindrically projected areas A and A are positively retained against movement from the two substantially-rectilinear stay portions 5 a and 5 b, respectively.

At the completion of this foaming, the upper and lower dies 20 and 10 are rotated away from each other relative to the hinge 6 to open the foaming die device 1. With this opening, it is to be understood that the right-side first and second semi-cylindrical protrusions 30 b and 40 b are disengaged from each other, while being simultaneously withdrawn outwardly from the first stay passage hole 2 a, whereas at the same time, the left-side first and second semi-cylindrical protrusions 30 b and 40 b are also disengaged from each other, while being simultaneously withdrawn outwardly from the second stay passage hole 2 b. Thus, all the semi-cylindrical protrusions 30 b and 40 b are automatically removed from all the two stay passage holes 2 a and 2 b at one time, when opening the foaming die device 1. Consequently, a resulting headrest HR is obtained, in which both two cylindrically projected areas A and A created about the respective first and second stay insertion holes 2 a and 2 b are firmly retained in the foam padding 3 and prevented from being exposed exteriorly of the trim cover assembly 2 at peripheral regions of the first and second substantially-rectilinear stay portions 5 a and 5 b, respectively. Hence, the outer appearance of the headrest HR is improved aesthetically.

Additionally, in accordance with the present invention, it is to be appreciated that the following advantages and effects are attained:

-   -   (i) Each of the left-side first and second semi-cylindrical         protrusions 30 b and 40 b as well as each of the right-side         first and second semi-cylindrical protrusions 30 b and 40 b is         so formed to become smaller in thickness as it proceeds to the         distal end thereof. This tapered configuration in effect permits         two lower halves of the first and second stay passage holes 2 a         and 2 b to smoothly slide on and along the right- and left-side         first semi-cylindrical protrusions 30 b and 30 b in the         longitudinal direction of the first and second         substantially-rectilinear stay portions 5 a and 5 b,         respectively, thereby being easily turned over along the curved         surface F of that semi-cylindrical protrusion 30 b relative to         the first stay passage hole 2 a and entered into the inside of         the trim cover assembly 2, while on the other hand permitting         two upper halves of the first and second stay passage holes 2 a         and 2 b to smoothly slide on and along the right- and left-side         second semi-cylindrical protrusions 40 b and 40 b in the         longitudinal direction of the first and second         substantially-rectilinear stay portions 5 a and 5 b,         respectively, thereby being easily turned over along the curved         surface F of that semi-cylindrical protrusion 40 b relative to         the second stay passage hole 2 b and entered into the inside of         the trim cover assembly 2. Thus, it is possible for a worker to         easily cause complete insertion of all the first and second         semi-cylindrical protrusions 30 a and 30 b into all the         corresponding stay passage holes 2 a and 2 b in assured manner.     -   (ii) The first and second stay receiving elements 30 and 40         themselves are provided independently of the lower and upper         dies 10 and 20, respectively. When those two stay receiving         elements 30 and 40 become worn out of use, it is easily possible         to replace them all or either of them by new corresponding stay         receiving element (s). Moreover, one or both of the two stay         receiving elements 30 and 40 can be modified in terms of         technical design and specifications, as required.     -   (iii) Also, the first and second stay receiving elements 30 and         40 can be easily secured to and removed from the lower and upper         dies 10 and 20, respectively, by use of the screws 1, which         enables a worker to easily replace one or both of those two stay         receiving elements 30 and 40 by a new corresponding stay         receiving element(s)

FIGS. 7 and 8 illustrate a second alternative embodiment of the present invention, wherein another stay receiving element 50 is provided, which has a toothed semi-cylindrical protrusion 50 a. This embodiment indicates that each of the foregoing first and second stay receiving elements 30 and 40 may be formed to have a toothed distal end. Namely, as far as the embodiment of FIGS. 7 and 8 is concerned, the stay receiving element 50 corresponds to the first stay receiving element 30, and therefore, the first stay receiving element 30 may be formed with a toothed semi-cylindrical protrusion identical to the toothed semi-cylindrical protrusion 50 a of the stay receiving element 50. The same goes for the second stay receiving element 40. In other words, it is to be understood that a first toothed semi-cylindrical protrusion 30 b and a second toothed semi-cylindrical protrusion 40 b may be provided in the lower and upper dies 10 and 20, respectively. It is noted that all like designations given in the FIGS. 7 and 8 correspond to all like designations in FIGS. 1 to 6, and any further description on common parts and elements between this second embodiment and the foregoing first embodiment shown in FIGS. 1 to 6 is omitted for the sake of simplicity of description. According to the present second embodiment, the toothed mode provides a plurality of pointed distal ends in each of the first and second semi-cylindrical protrusions 30 and 40. Such pointed distal ends are effective in reducing a coefficient of friction between the bottom wall 2 c of the trim cover assembly 2 and the first and second semi-cylindrical protrusions 30 b and 40 b. With this arrangement, it is to be appreciated that the right-side first and second semi-cylindrical protrusions 30 b and 40 b can be smoothly inserted in the first stay passage hole 2 a in a less frictional contact with the bottom wall 2 c of the trim cover assembly 2, and also, the left-side first and second semi-cylindrical protrusions 30 a and 40 a can be smoothly inserted in the second stay passage hole 2 b in a less frictional contact with the bottom wall 2 c.

Finally, it should be understood that the invention is not limited to the illustrated embodiment, but any modification, replacement and addition may be applied thereto, without departing from the scope of the appended claims. 

What is claimed is:
 1. A foaming process for forming a headrest, comprising the steps of: providing a foaming device comprising: a lower die having a first cavity region defined therein; an upper die having a second cavity region defined therein; said lower and upper dies being able to be mated with and separated from each other, wherein, when the lower and upper dies are mated with each other, a cavity is defined between said first and second cavity regions; a first protrusion provided in said lower die so as to protrude in a direction from an inner wall of the lower die towards said first cavity region; and a second protrusion provided in said upper die so as to protrude in a direction from an inner wall of the upper die towards said second cavity region; providing a headrest stay having at least one stay portion extending therefrom; providing a trim cover assembly having at least one stay passage hole adapted to allow said at least one stay portion to pass therethrough; wherein said at least one stay portion is so dimensioned to contact an end of said at least one stay passage hole, installing said headrest stay within said trim cover assembly, such that said at least one stay portion of the headrest stay passes through said at least one stay passage hole and extends outward from the trim cover assembly, in a sliding, close contact with said end of said at least one stay passage hole, thus causing concurrent stretching of said end of said at least one stay passage hole in an outward direction of the trim cover assembly and resulting in creation of a projected area in said end, said projected area protruding outward from said at least one stay passage hole and being laid on and about a part of the at least one stay portion located exteriorly of the trim cover assembly, so that the projected area is exposed outside of the trim cover assembly; loading said trim cover assembly with said headrest stay thus installed therein into either of said lower and upper dies; causing said lower and upper dies to mate together to define said cavity between said first and second cavity regions, with said trim cover assembly being accommodated in the cavity, such that said first and second protrusions are pressed against said projected area towards said at least one stay passage hole and forcibly inserted into between said at least one stay portion and said at least one stay passage hole, to the extent that the first and second protrusions are entered into the inside of the trim cover assembly, thereby causing the projected area itself to turn over at the first and second protrusions in relation to said at least one stay passage hole, thus resulting in reverse folding of the projected area from the at least one stay passage hole into the inside of said trim cover assembly on and along the first and second protrusions being entered into the inside of the trim cover assembly, whereby an entirety of the thus-turned-over projected area is displaced to the inside of the trim cover assembly together with the first and second protrusions, as a result of which, said entirety of the turned-over projected area is positioned within the trim cover assembly and also laid on the first and second protrusions entered in the trim cover assembly; thereafter, injecting a liquid foaming agent into the inside of said trim cover assembly and curing said liquid foaming agent into an increased mass of foam padding filled in the trim cover assembly, so that said turned-over projected area is sandwiched between said foam padding and both said first and second protrusions, within the trim cover assembly, whereupon a headrest with said at least one stay portion exposed outside thereof is formed in said cavity; and removing said headrest from said cavity by separating said lower and upper dies, during which, said first and second protrusions, provided in the lower and upper dies, respectively, are both automatically withdrawn outwards through between said at least one stay portion and said turned-over projected area secured to said foam padding and are eventually removed from said at least one stay passage hole, thereby producing a resultant headrest in which said turned-over projected area is retained inside of the resultant headrest, while said at least one stay portion is exposed outside of the resultant headrest.
 2. The foaming process according to claim 1, wherein each of said first and second protrusions is provided with: a distal end adapted to face said cavity; and a thickness that becomes small as it proceeds to said distal end, thereby not only facilitating insertion of said first and second protrusions into between said at least one stay passage hole and said at least one stay portion, but also facilitating said reverse folding of said projected area, at said step of causing said lower and upper dies to mate together.
 3. The foaming process according to claim 1, wherein each of said first and second protrusions is provided with a toothed end portion that is to face said cavity, said toothed end portion being adapted to reduce a coefficient of friction thereof against said projected area and said at least one stay passage hole, thereby not only facilitating insertion of said first and second protrusions into between said at least one stay passage hole and said at least one stay portion, but also facilitating said reverse folding of said projected area, at said step of causing said lower and upper dies to mate together.
 4. A foaming process for forming a headrest, comprising the steps of: providing a foaming device comprising: a lower die including: a first cavity region; a first mating surface; and a first stay receiving recession formed in said first mating surface; an upper die including: a second cavity region; a second mating surface adapted to be mated with said first mating surface; and a second stay receiving recession formed in said second mating surface; said upper and lower dies being able to be mated with and separated from each other, wherein, when the upper and lower dies are mated with each other, a cavity is defined between said first and second cavity regions; a first protrusion provided in said lower die at said first mating surface so as to protrude in a direction from an inner wall of the lower die towards said first cavity region, said first protrusion having a first recession communicating with said first stay receiving recession; and a second protrusion provided in said upper die at said second mating surface so as to protrude in a direction from an inner wall of the upper die towards said second cavity region, said second protrusion having a second recession communicating with said second stay receiving recession; providing a headrest stay having at least one stay portion extending therefrom; providing a trim cover assembly having at least one stay passage hole adapted to allow said at least one stay portion to pass therethrough; wherein said at least one stay portion is so dimensioned to contact an end of said at least one stay passage hole, installing said headrest stay within said trim cover assembly, such that said at least one stay portion of the headrest stay passes through said at least one stay passage hole and extends outward from the trim cover assembly, in a sliding, close contact with said end of said at least one stay passage hole, thus causing concurrent stretching of said end of said at least one stay passage hole in an outward direction of the trim cover assembly and resulting in creation of a projected area in said end, said projected area protruding outward from said at least one stay passage hole and being laid on and about a part of said at least one stay portion located exteriorly of the trim cover assembly, so that said projected area is exposed outside of the trim cover assembly; loading said trim cover assembly with said headrest stay thus installed therein into either of said lower and upper dies; placing said at least one stay portion in either of said first and second stay receiving recessions as well as in either of said first and second recessions; causing said lower and upper dies to mate together to define said cavity between said first and second cavity regions, with said trim cover assembly being accommodated in the cavity, while said first and second mating surfaces are mated with each other to cause mating of said first and second protrusions together, whereby said first and second stay receiving recessions are mated with each other, thereby embracingly receiving one part of said at least one stay portion therebetween, whereas at the same time, said first and second recessions are mated with each other, thereby embracingly receiving the other part of said at least one stay portion therebetween, such that the thus-mated first and second protrusions are pressed against said projected area towards said at least one stay passage hole and forcibly inserted into between said at least one stay portion and said at least one stay passage hole, to the extent that the mated first and second protrusions are entered into the inside of the trim cover assembly, thereby causing the projected area itself to turn over at the mated first and second protrusions in relation to said at least one stay passage hole, thus resulting in reverse folding of the projected area from the at least one stay passage hole into the inside of said trim cover assembly on and along the mated first and second protrusions being entered into the inside of the trim cover assembly, whereby an entirety of the thus-turned-over projected area is displaced to the inside of the trim cover assembly together with the mated first and second protrusions, as a result of which, said entirety of the turned-over projected area is positioned within the trim cover assembly and laid on and about the mated first and second protrusions entered in the trim cover assembly; thereafter, injecting a liquid foaming agent into the inside of said trim cover assembly and curing said liquid foaming agent into an increased mass of foam padding filled in the trim cover assembly, so that said turned-over projected area is sandwiched between the foam padding and the mated first and second protrusions, within the trim cover assembly, whereupon a headrest with said at least one stay portion exposed outside thereof is formed in said cavity; and removing said headrest from said cavity by separating said lower and upper dies, during which, said first and second protrusions, provided in the lower and upper dies, respectively, are both automatically withdrawn outwards through between said at least one stay portion and said turned-over projected area secured to said foam padding and are eventually removed from said at least one stay passage hole, thereby producing a resultant headrest in which said turned-over projected area is retained inside of the resultant headrest, while said at least one stay portion is exposed outside of the resultant headrest.
 5. The foaming process according to claim 4, wherein each of said first and second protrusions is provided with: a distal end adapted to face said cavity; and a thickness that becomes small as it proceeds to said distal end thereof, thereby not only facilitating insertion of said mated first and second protrusions into between said at least one stay passage hole and said at least one stay portion, but also facilitating said reverse folding of said projected area, at said step of causing said lower and upper dies to mate together.
 6. The foaming process according to claim 4, wherein each of said first and second protrusions is provided with a toothed end portion that is to face said cavity, said toothed end portion being adapted to reduce a coefficient of friction thereof against said projected area and said at least one stay passage hole, thereby not only facilitating insertion of said mated first and second protrusions into between said at least one stay passage hole and said at least one stay portion, but also facilitating said reverse folding of said projected area, at said step of causing said lower and upper dies to mate together.
 7. A foaming process for forming a headrest, comprising the steps of: providing a foaming device comprising: a lower die having a first cavity region defined therein; an upper die having a second cavity region defined therein; said upper and lower dies being able to be mated with and separated from each other, wherein, when the upper and lower dies are mated with each other, a cavity is defined between said first and second cavity regions; a first substantially-semi-cylindrical protrusion provided in said lower die so as to protrude in a direction from an inner wall of the lower die towards said first cavity region; and a second substantially-semi-cylindrical protrusion provided in said upper die so as to protrude in a direction from an inner wall of the upper die towards said second cavity region; providing a headrest stay having at least one substantially-columnar stay portion extending therefrom; providing a trim cover assembly having at least one substantially-circular stay passage hole adapted to allow said at least one substantially-columnar stay portion to pass therethrough; wherein said at least one substantially-columnar stay portion is so dimensioned to contact an entire end of said at least one substantially-circular stay passage hole, wherein said first and second substantially-semi-cylindrical protrusions are able to be mated with each other to embracingly receive said at least one substantially-columnar stay portion therebetween, installing said headrest stay within said trim cover assembly, such that said at least one substantially-columnar stay portion of the headrest stay passes through said at least one substantially-circular stay passage hole and extends outward form the trim cover assembly, in a sliding, close contact with said entire end of said at least one substantially-circular stay passage hole, thus causing concurrent stretching of said entire end of said at least one substantially-circular stay passage hole in an outward direction of the trim cover assembly and resulting in creation of a cylindrically projected area in said entire end, said cylindrically projected area protruding outward from said at least one substantially-circular stay passage hole and being laid on and about a part of the at least one substantially-columnar stay portion located exteriorly of the trim cover assembly, so that said cylindrically projected area is exposed outside of the trim cover assembly; loading said trim cover assembly with said headrest stay thus installed therein into either of said lower and upper dies; causing said lower and upper dies to mate together to define said cavity between said first and second cavity regions, with said trim cover assembly being accommodated in said cavity, while said first and second substantially-semi-cylindrical protrusions, provided in said lower and upper dies, respectively, are automatically mated with each other, thereby embracingly receiving said at least substantially-columnar stay portion therebetween, such that the thus-mated first and second substantially-semi-cylindrical protrusions are pressed against an entirety of said cylindrically projected area towards said at least one substantially-circular stay passage hole and forcibly inserted into between said at least one substantially-columnar stay portion and said at least one substantially-circular stay passage hole, to the extent that the mated first and second substantially-semi-cylindrical protrusions are entered into the inside of the trim cover assembly, thereby causing the cylindrically projected area itself to turn over at the mated first and second substantially-semi-cylindrical protrusions in relation to said at least one substantially-circular stay passage hole, thus resulting in reverse folding of said cylindrically projected area from the at least one substantially-circular stay passage hole into the inside of said trim cover assembly on and along the mated first and second substantially-semi-cylindrical protrusions being entered into the inside of the trim cover assembly, whereby an entirety of the thus-turned-over cylindrically projected area is displaced to the inside of the trim cover assembly together with the mated first and second substantially-semi-cylindrical protrusions, as a result of which, said entirety of the turned-over cylindrically projected area is positioned within the trim cover assembly and laid on and about the mated first and second substantially-semi-cylindrical protrusions entered in the trim cover assembly; thereafter, injecting a liquid foaming agent into the inside of said trim cover assembly and curing said liquid foaming agent into an increased mass of foam padding filled in the trim cover assembly, so that the thus-turned-over cylindrically projected area is sandwiched between the foam padding and the mated first and second substantially-semi-cylindrical protrusions, within the trim cover assembly, whereupon a headrest with said at least one substantially-columnar stay portion exposed outside thereof is formed in said cavity; and removing said headrest from said lower and upper dies by separating said lower and upper dies, during which, said first and second substantially-semi-cylindrical protrusions, provided in the lower and upper dies, respectively, are both automatically withdrawn outwards through between said at least one substantially-columnar stay portion and said turned-over cylindrically projected area secured to said foam padding and are eventually removed from the at least one substantially-circular stay passage hole, thereby producing a resultant headrest in which said turned-over cylindrically projected area is retained inside of the resultant headrest, while said at least one substantially-columnar stay portion is exposed outside of the resultant headrest.
 8. The foaming process according to claim 7, wherein each of said first and second substantially-semi-cylindrical protrusions is provided with: a distal end adapted to face said cavity; and a thickness that becomes small as it proceeds to said distal end thereof, thereby not only facilitating insertion of said mated first and second substantially-semi-cylindrical protrusions into between said at least one substantially-circular stay passage hole and said at least one substantially-columnar stay portion, but also facilitating said reverse folding of said cylindrically projected area, at said step of causing said lower and upper dies to mate together.
 9. The foaming process according to claim 7, wherein each of said first and second substantially semi-cylindrical protrusions is provided with a toothed end portion that is to face said cavity, said toothed end portion being adapted to reduce a coefficient of friction thereof against said cylindrically projected area and said at least one substantially-circular stay passage hole, thereby not only facilitating insertion of said mated first and second substantially-semi-cylindrical protrusions into between said at least one substantially-circular stay passage hole and said at least one substantially-columnar stay portion, but also facilitating said reverse folding of said cylindrically projected area, at said step of causing said lower and upper dies to mate together. 